Featured Case Study

Re-skilling Employees to Work in a Re-tooled Manufacturing Plant in North America

A major engine manufacturer located in North America

Business need
The client was faced with the challenge of a major new product release that required the re-tooling of its manufacturing facility, resulting in the need for employee re-skilling to support new technologies and processes. With over $1 billion for initial capital investment, with production goals of 6,000 engines per day across five product lines and with more than 2,250 salaried and hourly workers, including 1,500 new hires, the scale and complexity of training development and delivery had precluded any consideration for a single-source training supplier. After a preliminary analysis of the requirements, RPS offered a solution that continues to produce tangible results eight years after implementation.

How we helped
RPS worked with managers and employees at the manufacturing plant to clarify their learning needs and design, delivery and manage an integrated learning solution. To help the customer meet its accelerated production goals, RPS developed a master training plan that eliminated training redundancies and provided a multi-media learning approach that included instructor-led training, lab exercises, performance testing, mentoring activities, structured on-the-job training and e-learning. RPS provided a multi-skilled training workforce of its own employees to increase training capacity during peak demands for training.

RPS also developed a Web-based, systems-level work reference application, enabling plant skilled trades personnel to receive specific equipment diagnostic information right at the machine site on the plant floor. This in turn reduced plant down-time. The information generated was also linked to the plant’s preventive maintenance system for error tracking and continuous improvement.

Business results
By designing and executing an integrated, blended learning solutions, RPS helped its client achieve substantial cost savings, while boosting employee skills and knowledge. The manufacturer thus improved throughput as follows:


  • 100% of the operators were qualified prior to line engagement
  • The time-to-proficiency for operators was reduced by 60%
  • Improved response times led to reduced production downtime

RPS is proud of our partnership with this client and its accomplishments:


  • The client has supplied engines to five of the previous seven winners of the Motor Trend “Car and Truck Of The Year” awards
  • The Harbour Report has recognised the client’s facility as the most productive engine plant in North America